TDLAS architecture for widely spaced wavelengths

ABSTRACT

Systems for measuring a concentration of a target species include a first and second tunable diode laser generating laser light at a respective first and second wavelength each corresponding to respective absorption lines of the target species. A first optical fiber is optically coupled to the first tunable diode laser, and does not support a fundamental mode at the second wavelength. A second optical fiber is coupled to the second tunable diode laser and does not support a fundamental mode at the first wavelength. A fiber bundle includes respective distal ends of the first and second optical fibers, which are stripped of their respective coatings and arranged with their claddings adjacent to each other. A pitch head is configured to project respective optical beams from the fiber bundle through a measurement zone. A catch head located across the measurement zone receives the projected beams and directs them to a sensor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. application Ser.No. 16/441,881 filed on Jun. 14, 2019, now issued as U.S. Pat. No.10,830,698, which is a continuation application of U.S. application Ser.No. 15/538,156 filed on Jun. 20, 2017, now issued as U.S. Pat. No.10,352,852, which is a 35 U.S.C. § 371 national phase application ofPCT/US2015/061387 (WO 2016/105704), filed on Nov. 18, 2015, entitled“TDLAS Architecture for Widely Spaced Wavelengths”, which claims thebenefit of and priority to U.S. Provisional Application Ser. No.62/096,426, filed Dec. 23, 2014. Each of the aforementioned applicationsare incorporated herein by reference in their entireties.

COPYRIGHT STATEMENT

A portion of the disclosure of this patent document contains materialthat is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure as it appears in the Patent and TrademarkOffice patent file or records, but otherwise reserves all copyrightrights whatsoever.

BACKGROUND

Tunable diode laser absorption spectroscopy (TDLAS) is a well-proventechnique for detecting and measuring the concentrations of variousspecies in a gaseous mixture. TDLAS relies on the unique absorptionspectrum of the species being targeted to measure an attenuation of adiode laser beam at a very specific wavelength, tuned over an absorptionline of the species being measured, as it passes through a measurementregion. At wavelengths even slightly different from these absorptionlines, there is essentially no absorption.

Generally, in operation the wavelength of the diode laser beam isscanned over a small range that encompasses at least one absorption lineof the species of interest, as well as a region in which there is noabsorption. The light intensities of the light transmitted through thesample are measured by a photodetector. The photodetector signals arethen analyzed to obtain an average concentration of the target speciesover the length of the beam path with knowledge of the temperature.

Because the molecules of each target species absorb light at aparticular frequency, a different diode laser is generally required tomeasure different species. For certain applications, TDLAS systems needto use wavelengths encompassing a wide wavelength range fromapproximately 760 nm for oxygen (O₂) detection to 2.33 microns forcarbon monoxide (CO) detection. Wavelength-multiplexed TDLAS systemsexist that use wavelengths from 760 nm to 1559 nm with the 1559 nmwavelength used for CO detection. However, some applications require alower detection limit for CO than can be achieved at 1559 nm. Forinstance, in coal-fired boiler applications, the measurement path lengthcan be over 10 meters and in the combustion zone the CO concentrationcan range upward from 5000 ppm. Under these conditions, CO detectionusing the second overtone band in the 1550 nm region works adequately.Because this wavelength region is widely used in telecommunications,single-mode optical fiber with high transmission is readily available,along with robust fiber-optic components such as switches, lasers, andsplitters.

However, certain applications require detection capability for CO atmuch lower concentrations and over a much shorter path. For example,detection of CO in the range of 100 ppm over a one-meter path involvesmeasuring roughly a 500 times smaller effect on the light intensity ofthe transmitted beam, making detection substantially more difficult thanin the coal boiler application. This necessitates measuring CO on thefirst overtone at about 2.33 microns at which CO has a transition linestrength that is approximately 500 times higher than that at 1559 nm.

Recently, TDLAS systems have been deployed that operate at wavelengthsfrom 1350 nm to 2 microns. The extension to 2 microns allows sensitivedetection of CO₂ for carbon balance determination in steel applications.In many steel applications, O₂ need not be measured so the 760 nmwavelength is not required. In spite of this wavelength range extension,the same single-mode fiber can be used to transmit, in single-modefashion, light in this entire wavelength range (1350 nm-2000 nm).However, further extension to about 2.33 microns for sensitive COdetection, and a requirement to measure O₂ at 760 nm necessitates acompletely different architecture due to the inability of a single typeof single-mode fiber to deliver wavelengths from about 760 nm to 2.33microns single mode with high transmission and low bend loss.

Since light at wavelengths from about 760 nm-2.33 microns cannotco-propagate on the same single-mode fiber, a new wavelengthmultiplexing scheme must be devised for applications requiring both O₂detection and sensitive CO detection. One such application is glassfurnace monitoring. Three wavelengths are required to measure O₂, water(H₂O), and CO for this application with CO detection required at the 100ppm level or lower. Also required for this application is the ability tomeasure across approximately 10 paths simultaneously, or nearlysimultaneously.

SUMMARY

According to various sets of embodiments, a system, apparatus, andmethod for TDLAS for widely spaced wavelengths is provided.

In an aspect, a system for measuring a concentration of a target speciesincludes a first and second tunable diode laser generating laser lightat a first wavelength and a second wavelength respectively eachcorresponding to respective absorption lines of the target species. Thesystem also includes a first fiber, a second fiber, a fiber bundle, apitch head, a sensor, and a catch head. The first fiber has a proximalend and a distal end, is optically coupled to the first tunable diodelaser at the proximal end, and does not support a fundamental mode atthe second wavelength. The second fiber has a proximal end and a distalend, is coupled to the second tunable diode laser at the proximal end,and does not support a fundamental mode at the first wavelength. Thefiber bundle includes respective distal ends of the first and secondfibers, which are stripped of their respective coatings and arrangedwith their claddings adjacent to each other forming a bundledconfiguration. The pitch head includes a transmitting optic opticallycoupled to the first and second tunable diode lasers via the distal endsof the first and second fibers of the fiber bundle. The pitch head isconfigured to project respective optical beams from the first fiberoptic core and the second fiber optic core, wherein the pitch head isoriented to project the respective beams from each of the first andsecond fiber optic cores through a measurement zone. The sensor includesa photodetector configured to detect an optical power of light in thefirst and second wavelengths. The catch head (i) is located across themeasurement zone by a select distance from the pitch head, and (ii) inoptical communication with the pitch head to receive the respectivebeams of the first and second fiber optic cores and direct therespective beams to the sensor.

Various modifications and additions can be made to the embodimentsdiscussed without departing from the scope of the invention. Forexample, while the embodiments described above refer to particularfeatures, the scope of this invention also includes embodiments havingdifferent combination of features and embodiments that do not includeall of the above described features.

BRIEF DESCRIPTION OF DRAWINGS

A further understanding of the nature and advantages of particularembodiments may be realized by reference to the remaining portions ofthe specification and the drawings, in which like reference numerals areused to refer to similar components. In some instances, a sub-label isassociated with a reference numeral to denote one of multiple similarcomponents. When reference is made to a reference numeral withoutspecification to an existing sub-label, it is intended to refer to allsuch multiple similar components.

FIG. 1 illustrates a fiber bundle assembly for pitch heads in a widelyspaced wavelength TDLAS system;

FIG. 2 illustrates a dual band photodetector for use in a widely spacedwavelength TDLAS system;

FIG. 3 illustrates a system block diagram for a widely spaced wavelengthTDLAS system;

FIG. 4 is a flow chart for a method of utilizing widely spacedwavelength TDLAS;

FIG. 5 illustrates beam divergence from a fiber bundle assembly in awidely spaced TDLAS system;

FIG. 6 is a block diagram of a control system as used in a widely spacedwavelength TDLAS system; and

FIG. 7 illustrates a dichroic beam combiner for pitch or catch heads ina widely spaced wavelength TDLAS system.

DETAILED DESCRIPTION

While various aspects and features of certain embodiments have beensummarized above, the following detailed description illustrates a fewembodiments in further detail to enable one of skill in the art topractice such embodiments. The described examples are provided forillustrative purposes and are not intended to limit the scope of theinvention.

In the following description, for the purposes of explanation, numerousspecific details are set forth in order to provide a thoroughunderstanding of the described embodiments. It will be apparent to oneskilled in the art, however, that other embodiments of the presentinvention may be practiced without some of these specific details.Several embodiments are described herein, and while various features areascribed to different embodiments, it should be appreciated that thefeatures described with respect to one embodiment may be incorporatedwith other embodiments as well. By the same token, however, no singlefeature or features of any described embodiment should be consideredessential to every embodiment of the invention, as other embodiments ofthe invention may omit such features.

Unless otherwise indicated, all numbers used herein to expressquantities, dimensions, and so forth used should be understood as beingmodified in all instances by the term “about.” In this application, theuse of the singular includes the plural unless specifically statedotherwise, and use of the terms “and” and “or” means “and/or” unlessotherwise indicated. Moreover, the use of the term “including,” as wellas other forms, such as “includes” and “included,” should be considerednon-exclusive. Also, terms such as “element” or “component” encompassboth elements and components comprising one unit and elements andcomponents that comprise more than one unit, unless specifically statedotherwise. As is well known in the art, the same device may typically beused for either multiplexing or demultiplexing, depending upon thedirection of the light which passes through it. Consequently, the term“multiplexer” or “mux” as used herein will be understood to include bothmultiplexing and demultiplexing functions.

Conventional wavelength division multiplexing (WDM) techniques cannot beused to multiplex signals having wavelengths that span the range of 760nm-2330 nm into a single-mode fiber, as it would be extremely difficultto create or find a suitable output fiber to carry multiple signalsspanning the range of wavelengths.

Fiber Bundle TDLAS Architecture

FIG. 1 illustrates a fiber bundle assembly 100 capable of transmittingbeams at wavelengths spanning the 760 nm-2330 nm range, in single modeoperation, from a single transmitting (pitch) head, and to acorresponding single receiving (catch) head. The fiber bundle assembly100 includes a fiber bundle 105 comprising the cores 135 a, 135 b, 135 c(135 collectively) of three single-mode optical fibers 110, 115, 120.Each of the single-mode optical fibers 110, 115, 120 has a distal andproximal end. The single-mode optical fibers 110, 115, 120 are opticallycoupled at their proximal ends to a respective tunable diode laser. Eachrespective tunable diode laser may be tuned to generate laser light at aselected wavelength. These wavelengths may be chosen to correspond withthe absorption lines of one or more target species.

Each wavelength of laser beam is carried by a respective single-modefiber 110, 115, 120 appropriate for that wavelength. For example,according to one set of embodiments, the single-mode fiber 110 carries2330 nm wavelength light, single-mode fiber 115 carries 1350 nm light,and single-mode fiber 120 carries 760 nm light. In further embodiments,SM1950 optical fiber may be used for single-mode fiber 110 to carry 2330nm light, SMF28e optical fiber may be used for single-mode fiber 115 tocarry 1350 nm light, and SM750 optical fiber may be used for single-modeoptical fiber 120 to carry 760 nm light. In embodiments utilizing SM1950optical fiber, light at 2330 nm experiences loss at 1 dB/m. However,this level of loss may be acceptable over short lengths.

The three single-mode fibers 110, 115, 120 are combined, at couplingjoint 165, to form fiber bundle 105. According to one set ofembodiments, the distal ends of each of the single-mode optical fibers110, 115, 120 are stripped of their coating 125. In various embodiments,the coating 125 removed may include, without limitation, some or all ofthe jacketing or buffer material of the optical fiber, but is notintended to include the cladding immediately adjacent to the core. Thestripped optical fibers 110, 115, 120 are then arranged in a triangularconfiguration 130 and bundled to form fiber bundle 105 with theirrespective claddings abutting. In some embodiments, coupling joint 165may provide a protective structure around the point at which the threestripped optical fibers 110, 115, 120 meet to form the fiber bundle 105.The coupling joint 165 may further stabilize or keep the optical fibers110, 115, 120 in place relative to the fiber bundle 105. In someembodiments, cores 135 are bundled in a triangular configuration 130 inwhich the cores 135 are spaced apart by 125 microns—the thickness of thecladding 140 between two adjacent optical fibers 110, 115, 120. In analternative set of embodiments, a multi-core fiber may be substitutedfor the bundled fibers. In various embodiments, the fiber bundle 105 mayfurther comprise a jacket, buffer, or other encasing applied to thebundled configuration of the fiber optic cores 135 for further physicalprotection of the exposed cores, to maintain the triangularconfiguration of the cores, and to improve signal characteristics. Anachromatic doublet (not shown), or other suitable optical collimator,can be used to collimate the light from the fiber bundle 105. However,due to the lateral offset of the light in the focal plane, the beamsdiverge after exiting the collimator by about 2 milliradians (125microns/50 mm f.1.). Thus, each of the different wavelengths of laserbeams will arrive at a catch side at a different location, depending onthe path length. This is illustrated and described in more detail belowwith respect to FIG. 6.

Thus, the fiber bundle assembly 100 may require a system to maintainalignment between the pitch and catch side optics. An example of such analignment system is described in U.S. Pat. No. 7,248,755 ('755 Patent),entitled “Method and Apparatus for the Monitoring and Control ofCombustion,” which is incorporated herein by reference in its entirety.The auto-alignment system described in the '755 patent overcomes suchmisalignment issues by automatically and dynamically adjusting the tipand tilt of either the pitch side optical head or the catch side opticalhead, or both pitch and catch side optical heads, to maintain alignmentand ensure an adequate signal is received at each frequency. Theauto-alignment system is described in more detail below with respect toFIG. 6.

In some embodiments, each wavelength laser beam may require realignmentof the pitch and/or catch optics by the auto-alignment system. In suchembodiments, time-division multiplexing (TDM) may be appropriate. Byadopting TDM instead of a WDM based system, the need to performwavelength demultiplexing in the catch head can be avoided. Aconventional wavelength demultiplexer requires the use of additionaloptical fiber in the catch head. However, at a wavelength of 2330 nm,additional optical fiber can highly attenuate the received signal.

Each of the input connectors 155 a, 155 b, 155 c (155 collectively) arecoupled to a respective light source (not shown). For example, invarious embodiments, input connector 155 a may couple single-modeoptical fiber 110 to a 2330 nm wavelength light source, input connector155 b may couple single-mode optical fiber 115 to a 1350 nm wavelengthlight source, and input connector 155 c may couple single-mode opticalfiber 120 to a 760 nm wavelength light source. The fiber bundle 105 isthen coupled by an output connector 160 to the pitch head or atransmitting optic.

In operation, each of the light sources may be turned on and off in analternating fashion following a TDM scheme so that only one light sourceis transmitted at a given time. For example, in various embodiments, afirst light source generating light at about 2330 nm may be turned on.The 2330 nm signal is carried by single-mode optical fiber 110, and aspart of fiber bundle 105 on the respective core 135 corresponding tooptical fiber 110, to a transmitting optic. The first light source isthen turned off, and a second light source generating light at 1350 nmis turned on. The 1350 nm signal is then carried by single-mode opticalfiber 115, and as part of fiber bundle 105 on the respective core 135corresponding to optical fiber 115, to a transmitting optic. The secondlight source is then turned off, and a third light source generatinglight at 760 nm is turned on. The 760 nm signal is then carried bysingle-mode optical fiber 120, and as part of fiber bundle 105 on therespective core 135 corresponding to optical fiber 120, to atransmitting optic. Alternatively a 1×2 optical switch can be used toswitch the light from each of the laser sources into the appropriate legof the single mode fiber bundle or to a dummy optical path, so thatlight at only a single wavelength is present at the distal end of thefiber bundle at a time. The switched embodiment allows for more stableoperation of the diode lasers.

Using optical fiber to catch and transmit the light back to a centrallylocated rack for detection and quantification becomes problematic whenusing the long wavelength of about 2330 nm for CO detection, as thiswavelength suffers high attenuation in silica fibers (˜1 dB/m). Forexample, arrangements may have a system deployed at a refinery wherecatch heads may be mounted on different furnaces that can, in manyinstances, be separated by a distance of 1 kilometer or more. Thisrequires too much fiber to be able to detect the transmitted light at2330 nm, with transmission loss on the order of approximately 1×10¹⁰⁰for 1 kilometer of fiber. The other issue with long runs of multimodecatch fiber is that mode noise generated by interference effects in thefiber creates transmission noise that impedes detection, fitting, andquantification of absorption peaks.

FIG. 2 illustrates a cross-sectional schematic view of a dual banddetector 200 that may be used within, or in close proximity to, thecatch heads in combination with a time-division multiplexing strategy todetect each of a first received signal 220, second received signal 225,and third received signal 230 at each wavelength respectively associatedwith the received signals 220, 225, 230, without having to use awavelength demultiplexer. Thus, dual band detector 200 addresses thepotential attenuation of 2330 nm wavelength light carried over longlengths of fiber by allowing detection, digitization, and/or signalprocessing to occur in the catch head. The resulting data can betransmitted back to a central rack for final processing andquantification via Ethernet protocol on either copper or optical fibermedia.

The dual band detector 200 comprises a sandwiched detector assembly 205with a first photodetector layer 210 and a second photodetector layer215. Each of the first and second photodetector layers 210, 215 areconfigured so that each of the respective wavelengths of each receivedsignal 220, 225, 230 can be detected. For example, in some embodiments,the first photodetector layer 210 may be a silicon (Si) PINphotodetector layer and the second photodetector layer 215 may be anextended indium gallium arsenide (ex-InGaAs) photodetector for detectingthe first received signal 220 having a wavelength of 760 nm, a secondreceived signal 225 having a wavelength of 1350 nm, and a third receivedsignal 230 having a wavelength of 2330 nm. The 760 nm light from thefirst received signal is detected well by the Si PIN photodetector 210,however wavelengths in the near-infrared (˜1-3 microns), including thewavelengths of the second and third received signals 225, 230, passthrough the Si PIN photodetector 210 undetected. Thus, the longerwavelengths impinge on the second photodetector layer, the ex-InGaAsphotodetector 215, which is sensitive from about 1.3 microns to 2.5microns. However, the ex-InGaAs photodetector 215 cannot distinguishbetween the second received signal 225 and the third received signal 230without recourse to more complicated techniques such as frequencydivision multiplexing (FDM), i.e. modulating the second and thirdreceived signal at two different frequencies and discriminating based onthe frequency of the detected light. Thus, without FDM, the dual banddetector 200 cannot be used for detecting the signals simultaneously. Byutilizing TDM, as suggested above for use with fiber bundle assembly100, only one of the three received signals 220, 225, 230 will be turnedon at any given time, eliminating the need to physically separate the1350 nm and 2330 nm beams of second received signal 225 and thirdreceived signal 230. In this manner, the use of TDM and the dual banddetector can eliminate the need for demultiplexing at the receivingside.

FIG. 3 is a block diagram of a widely spaced wavelength TDLAS system300, according to various embodiments. The widely spaced wavelengthTDLAS system 300 comprises a first laser source 305, second laser source310, and third laser source 315 for generating laser light at aparticular wavelength. For example, laser sources 305, 310, 315 may be aseries of tunable diode lasers. Each of the first, second, and thirdlaser sources 305, 310, 315 are configured to generate a laser beam of aspecific wavelength that corresponds to an absorption line in anabsorption spectrum for each species of interest in the measurementzone. For example, in some embodiments, the first laser source 305generates a laser beam at 760 nm corresponding to the detection ofoxygen molecules (O₂), the second laser source 310 generates a laserbeam at 1350 nm corresponding to the detection of water molecules (H₂O),and the third laser source 315 generates a laser beam at 2330 nmcorresponding to the detection of carbon monoxide (CO) molecules. Inthis example, only three laser sources are provided by way ofillustration, and it is to be understood that in other embodiments, anynumber of laser sources may be used to generate laser beams at any othernumber of selected absorption line wavelengths. In some embodiments,each of the laser sources 305, 310, 315 are centrally housed andcontrolled in a rack or cabinet that may be located remotely away from ameasurement site.

The signals from each of the laser sources 305, 310, 315 are opticallycoupled to a plurality of pitch heads 320 a-320 n. In some embodiments,the signals from each of the laser sources 305, 310, 315 are switchedbetween each of the plurality of pitch heads 320 a-320 n to makemeasurements along each of the multiple paths A-A through N-N. To ensuresingle-mode behavior, an optical switch 327 may be provided for eachwavelength of light to each pitch head 320 a-320 n, to allow onewavelength to be transmitted, in a serial manner, from each pitch head.

Alternatively, some embodiments call for the signals from each of thelaser sources 305, 310, 315 to be split along each of the multiple pathsso as to provide the respective laser beams to each of the plurality ofpitch heads 320 a-320 n in parallel (simultaneously). Widely spacedwavelength TDLAS systems are often used in measurement zones that areessentially particle free, such as glass furnaces and other natural gasfired furnaces, resulting in negligible laser power attenuation causedby the furnaces themselves. Thus, the light from the laser sources 305,310, 315 can be split to service the multiple paths in parallel ratherthan switching the light serially between each pitch head 320 a-320 n,which is required for high scattering applications like coal and steelelectric arc furnaces where laser power attenuation is sufficiently highthat all power must be available to measure on every path. Incombination with a time multiplexing strategy described above, all pathsA-A through N-N can be measured simultaneously for a species, andswitching can occur between the measured species (i.e. wavelength)rather than between the multiple paths.

Fiber bundle assemblies 325 a-325 n are provided for delivering each ofthe laser beams from each of the laser sources 305, 310, 315 to acorresponding pitch head 320 a-320 n. In one set of embodiments, thesignals from each of the laser sources 305, 310, 315 are carried over arespective single-mode fiber corresponding to the wavelength of eachsignal, as described with respect to FIGS. 1 & 2 above. The fiber bundleassemblies 325 a-325 n then transmit each of the laser beams to producea discrete time division multiplexed signal having only one wavelengthbeam at a given time. Single mode operation is maintained over theentire range of wavelengths and delivered to a single set of pitchoptics in the pitch heads 320 a-320 n.

The pitch heads 320 a-320 n may include a collimator or other pitchoptics to project the discrete time division multiplexed beams acrossmeasurement zone 330. Each respective catch head 335 a-335 n is spaced,across the measurement zone 330, from a corresponding pitch head 335a-335 n. Each of the pitch heads 320 a-320 n is aligned with arespective catch head 335 a-335 n such that each discrete time divisionmultiplexed beam is received by the catch head. In some embodiments, thepitch and/or catch heads are aligned via an auto-alignment system asdescribed in the '755 patent, and in further detail with respect to FIG.6 below.

In various embodiments, catch heads 335 a-335 n may also optionallycomprise respective fiber bundle assemblies 340 a-340 n for receivingeach of the time-division multiplexed beams. For example, in someembodiments, a fiber bundle assembly 340 a-340 n may be used such that acore corresponding to the particular wavelength of the transmittedsignal is aligned to receive the beam. For example, in some embodiments,the catch head 335 a may include a lens that focuses thewavelength-bundled beam onto the appropriate fiber of the fiber bundle.The auto-alignment system may then adjust the lens, catch side fiberbundle assembly 340 a, pitch side fiber bundle assembly, pitch head, ora combination of these elements to align the beam to the catch sidefiber bundle assembly 340 a.

The received beam is directed by the catch head 335 a-335 n onto arespective photodetector 345 a-345 n. In some embodiments, acorresponding single-mode fiber is used to carry each wavelength of thesignal. In other embodiments, the signal may be received, and carriedby, a multi-mode fiber. In various embodiments, the photodetector 345a-345 n may be in close proximity to the catch head 335 a-335 n so as tominimize the lengths of optical fiber used to carry the signal from thecatch head 335 a-335 n to the photodetector 345 a-345 n. In some furtherembodiments, a photodetector 345 a-345 n may be provided within eachcatch head 335 a-335 n, such that receiving optic(s) in each catch head335 a-335 n focuses the received beam directly onto the respectivephotodetector 345 a-345 n.

Each photodetector 345 a-345 n is configured to detect and measure thelight intensities of each wavelength of light received. In oneembodiment, the photodetectors 345 a-345 n are dual band photodetectors200 as described in FIG. 2. The measurements from the photodetectors 345a-345 n are then transmitted back to a control system 350 for furtherprocessing and analysis. In some embodiments, the control system 350 maybe located on a central rack and data may be transmitted back to thecentral rack directly over a physical link such as copper or opticalfiber media, or through communications network that includes withoutlimitation a local area network (LAN). a wide area network (WAN), avirtual network, the internet, an intranet, or a personal area network.Connection to the communications network may be either wired orwireless. In various embodiments, the control system 350 may be used aspart of a feedback loop to control the combustion environment in themeasurement zone 330. In some embodiments, some processing (e.g.waveform averaging) of the received signal may occur in the heads by,for example, a field programmable gate array (“FPGA”) to minimize thebandwidth transmission requirements back to the control system.

FIG. 4 is a flow chart of a method for widely spaced wavelength TDLAS400 according to various embodiments. At block 405, laser beams areselected at select absorption line wavelengths of targeted species. Insome embodiments, the laser beams may be generated following a TDMscheme that switches between each laser beam to be generated, asdescribed in further detail below with respect to block 420, while inother embodiments, the laser beams may be generated simultaneously. Inone embodiment, laser beams are generated at at least a firstwavelength, such as one corresponding to the detection of CO at levelsof 100 ppm, and a second wavelength, such as one corresponding to thedetection of O₂. In this example, the first and second wavelengths mayalso be so widely spaced such that they cannot be carried by a commonsingle-mode fiber.

Instead, at block 410, each of the laser beams are carried over arespective single-mode optical fiber for each particular wavelength oflaser beam. The beams are carried by the respective single-mode opticalfibers to a fiber bundle assembly. For example, in some embodiments, apitch head may comprise all or part of the fiber bundle assembly. Inother embodiments, the fiber bundle assembly may be separate from thepitch head.

At block 415, the optical fibers are arranged into a fiber bundleassembly. As described with respect to FIG. 1, above, in variousembodiments, the distal ends of each of the optical fibers are strippedof their coatings, and, with their claddings and cores intact, arrangedinto a triangular configuration. This triangular configuration ispackaged to form the fiber bundle.

At block 420, the fiber bundle assembly transmits a probe signal througha measurement zone. The probe signal may comprise component signals ateach of the selected wavelengths respectively, with each componentsignal carried over the corresponding single-mode optical fibers. Invarious embodiments, only one wavelength of component signal may betransmitted via the fiber bundle assembly at a given time, following aTDM sequence.

At block 425, the probe signal is received at a catch head, spacedacross the measurement zone, from the pitch head. In variousembodiments, the catch head may use one or more receiving optics todirect the probe signal to a multimode fiber, respective single modefiber, fiber bundle assembly, photodetector, or otherwise as appropriatefor the specific configuration of the catch head. For example, in someembodiments, the catch head may employ a corresponding fiber bundleassembly that can be used to receive each wavelength of component signalwith a single-mode optical fiber corresponding to that wavelength. Infurther embodiments, the catch head may also employ an auto-alignmentsystem, as described in the '755 patent, which dynamically adjusts thecatch head tilt and tip in order to maintain alignment with the pitchhead based on detected light intensities of the receivedwavelength-bundled beam. In some embodiments, a photodetector may beprovided within the catch head, and the catch head may direct thereceived wavelength-bundled beam through free space (air) directly tothe internal photodetector.

At block 430, each component wavelength of the probe signal is detected.To accomplish this, a single photodetector assembly may be provided thatis capable of detecting each component wavelength, such as by using aTDM system in combination with the dual band photodetector 200 describedwith respect to FIG. 2. Alternatively, a separate photodetector may beused that is sensitive to each selected wavelength respectively.

At block 435, a light intensity is determined for each respectivecomponent wavelength via the photodetector. The light intensity can thenbe further processed by other components, located in the catch head orseparately at a remote site, to determine a relative concentration of atargeted species in the measurement zone, over the path of the probesignal.

At optional block 440, one or more combustion parameter is adjustedbased on a measured concentration of at least one species in themeasurement zone. Combustion parameters may include, without limitation,a fuel composition, concentration, quantity, air to fuel ratio, or otherfuel related parameter; air intake or valve parameters; overall furnacetemperature; voltage supplied to an electrode in an electric arcfurnace; or any other input parameter affecting the combustionproperties within the measurement zone.

In one set of embodiments, a control system may adjust one or morecombustion parameters based on the determination of the concentration ofvarious targeted species. In some embodiments, the targeted species maybe indicative of various characteristics of the combustion process, suchas combustion balance, efficiency, and emissions generated by thecombustion process. For example, the air to fuel ratio may be adjustedcorresponding to the measured concentration of CO and O₂; a fuelconcentration may be adjusted corresponding to the measuredconcentration of CO, CO₂, O₂, or combination of CO, CO₂, and O₂; and soon. A combustion parameter may be adjusted based on a correspondingmeasured concentration of at least one species.

In further embodiments, the combustion parameters may be adjustedindependently in each area of the measurement zone based on measurementscorresponding to the respective areas of the measurement zone. Forexample, a measured concentration derived from the measurements of twoor more pairs of pitch and catch heads may correspond to an area of themeasurement zone defined by the respective measurement path of each pairof pitch and catch heads. Thus, based on the measured concentrations inthe above defined area, combustion parameters may be adjusted locally inthe defined area. For example, one or more burners in a conventionalfurnace that most directly affect the defined area may be identified andthe combustion parameters may be adjusted for the identified burnersindependently.

FIG. 5 schematically depicts the beam divergence from the various coresof a fiber bundle assembly in widely spaced wavelength TDLAS system 500.The widely spaced wavelength TDLAS system 500 includes a pitch sidefiber bundle assembly 505 positioned behind a transmit collimating optic530, receive lens 535, and catch head 555. The catch head may optionallyinclude a photodetector 560, depicted in phantom lines. As describedabove with respect to FIG. 1, each pitch side fiber bundle assembly 505includes a fiber bundle having three single-mode optical fibers. Eachsingle-mode optical fiber carries a respective wavelength of laser. Eachof the single-mode optical fibers are stripped of their coating andarranged in a triangular configuration. An achromatic doublet (notshown), or other suitable collimating optic 530 may be used to collimatethe light from the fiber bundle.

Due to the lateral offset of the light in the focal plane, each of thebeams will slightly diverge and will be focused by the lens 535 at adifferent position in the focal plane of the catch head optic,increasing linearly with increasing distance between the pitch and catchheads. This lateral offset is illustrated by the divergence cones 515,520, 525 originating from each of the cores respectively. The opticalpaths X-X, Y-Y, and Z-Z correspond to the beams of each of the threecones 515, 520, 525. Therefore, when focused by the lens 535, each beamis focused to a different point in space. For example, the beamoriginating from the uppermost fiber of the triangular bundleconfiguration, having divergence cone 515, and taking optical path X-X,is focused at a position indicated by point 540. The beam from the lowerright fiber, having divergence cone 520, and traveling along opticalpath Y-Y, is focused at the position indicated by point 545. The beamfrom the lower left fiber, having divergence cone 525, and travelingalong optical path Z-Z, is focused at the position indicated by point550. Thus, when the beams reach the catch head 555, the catch head 555must be aligned to receive the signal at the points 540, 545, 550corresponding to the transmitted beam. In various embodiments, the catchhead may include the auto-alignment system described in the '755 patent,and as described in further detail with respect to FIG. 6 below. In someembodiments, the catch head 555 may simply include a photodetector 560for detecting each of the transmitted wavelengths, thus the catch head555, pitch head (not shown), or both are adjusted such that the beamsare received by the sensor. Thus, the photodetector 560 must bepositioned such that the photodetector 560 will receive the respectivebeams at point 540 during the window of time that it is transmitted, atpoint 545 during the time window that it is transmitted, and at point550 at the appropriate time windows.

In an alternative set of embodiments, the beams may be directed towardsa respective fiber in the catch head. For example, in some embodiments,the catch head may include a catch side fiber bundle assembly, where thecatch head 555, catch side fiber bundle assembly, pitch head (notpictured), pitch side fiber bundle assembly 505, or a combination theseelements must be aligned by the auto-alignment system such that eachwavelength of the beam is received by a respective fiber core of thefiber bundle of the catch side fiber bundle assembly. For example, insome embodiments, the top most fiber of the catch side fiber bundleassembly may correspond to, or be the same type of fiber as, the topmost fiber of the pitch side fiber bundle assembly 505. Similarly, thebottom left fibers may correspond to one another, and bottom rightfibers may also correspond to one another.

FIG. 6 is a system block diagram of an auto-alignment system 600 for awidely spaced TDLAS system. The auto-alignment system 600 includes apitch head 605, coupled to a pitch head platform 675, and in opticalcommunication with a catch head 620, the catch head 620 coupled to acatch head platform 665. Pitch head 605 transmits an optical signal tocatch head 620 via optical path 1-1. The pitch head 605 includestransmitting optic 610, and, in various embodiments, may optionallyinclude fiber bundle assembly 615. The catch head 620 includes receiveoptic 625, an optional fiber bundle assembly 630 (shown in phantomlines), and sensor 635.

The pitch head platform 675 is coupled to one or more control devices670, and catch head platform 665 is coupled to one or more controldevices 660. Each of the control devices 660, 670 are communicativelycoupled to an electronic controller 655. The electronic controller 655is coupled to the control system 640. The sensor 635 of catch head 620is also communicatively coupled to the control system 640 providingmeasurement data to the control system 640 for feedback based alignmentcontrol among other calculations and functions based on the measuredsignals. In various embodiments, the sensor 635 includes a dual banddetector as described above with respect to FIG. 2. The control system640 includes processor 645, memory 650, and computer readable media 680.The control system may include various software elements and computerinstructions which may be stored on a computer readable medium 680 andloaded into system memory 650. System memory 650 may include, withoutlimitation, random access memory (RAM) or read-only memory (ROM), whichcan be programmable, flash-updateable, or the like.

Each catch and pitch head is attached respectively to catch and pitchhead platforms 665, 675. The catch and pitch head platforms 665, 675 areadjustable along at least two axes of freedom. For example, in one setof embodiments, the catch and pitch head platforms may allow tip andtilt about axes orthogonal to the optical axis 1-1, and rotation aboutthe optical axis 1-1. In further embodiments, the catch and pitch headplatforms 665, 675 may also move laterally, along a plane orthogonal tothe optical axis 1-1, and move forward and backward, transversely alongthe optical axis 1-1. Tip, tilt, rotation, lateral and on-axis movementsmay be actuated by one or more respective control devices 660, 670. Thecontrol devices 660, 670 include, without limitation, servo motors,stepper motors, pneumatic actuators, hydraulic actuators, or any otherelectro-mechanical means of actuation for adjusting the position of thecatch and pitch head platforms 665, 675. According to another set ofembodiments, each of the components of the pitch and catch heads 605,620 may be controlled independently, with each component mounted onseparate adjustable stages. For example, in various embodiments, any orall of the transmitting optic 610, fiber bundle assembly 615, pitch head605, receiving optic 625, optional catch side fiber bundle assembly 630,photodetector 635, and catch head 620 may be mounted on independentadjustable stages.

The control devices 660, 670 may be controlled by an electroniccontroller 655. During system alignment, various embodiments call forthe control system 640 to monitor the optical power of the receivedlaser light that is detected by sensor 635. Misalignment will decreasethe optical power of the received signal. During auto-alignment, thecontrol system 640 measures the detected signal from sensor 635 anddirects the electronic controller 655 to cause one or both of thecontrol devices 660, 670 to move a predetermined displacement in onedirection. The control system 640 then re-measures the detected signal.If the signal increases, then the control system 640 directs theelectronic controller 655 to cause the control device 660, 670 tocontinue moving in steps in the same direction until the signal does notincrease any further. The control system 640 will then direct theelectronic controller 655 to cause the other control devices of the oneor more control devices 660, 670 to move along an axis orthogonal to theprevious axis. Tip, tilt, lateral, and transverse movements may be madein this manner to align the pitch and catch heads 605, 620. In this way,the sensor 635 provides feedback to the control system 640 forauto-alignment purposes. In other embodiments, the pitch and catch headsmay be aligned along multiple axes simultaneously, in alternatingfashion, or sequentially, one axis at a time. In some embodiments, thecontrol system 640 may merely relay the measured signal levels to theelectronic controller 655, with which the electronic controller 655 maythen conduct the alignment procedure. In other embodiments, the controlsystem 640 may directly send control signals to the control devices 660.670 without need for electronic controller 655. In various embodiments,the control system 640 may move the catch head platform 665 and pitchhead platform 675 independently or in a combined manner.

Due to the lateral offset of the fiber cores of the fiber bundleassembly (i.e. an offset in the focal plane). each of the transmittedbeams will slightly diverge. Thus, when decollimated by the receivingoptic 625, the beams will be focused at different points in space. Thus,when auto-aligned by the system, multiple alignments may be necessarycorresponding to each of the signals from each of the cores of the fiberbundle. In some embodiments, the control system 640 may run theauto-alignment procedure for each wavelength beam corresponding to eachrespective fiber core. Thus, the catch head 620 must be aligned suchthat sensor 635 receives the corresponding wavelength beam from thepitch side fiber bundle assembly 615.

In various embodiments, the auto-alignment procedure may be conductedbefore actual operation, and alignment positions for each receivedwavelength beam may be stored by the electronic controller 655 and/orcontrol system 640, and the catch head 620 may be adjusted to each ofthe stored positions corresponding to the transmitted wavelength beam.In other embodiments, the alignment of the catch head 620 may beadjusted in real-time as each beam is transmitted.

In one aspect, embodiments may employ the control system 640 to performmethods in accordance with various embodiments of the invention.According to a set of embodiments, some or all of the procedures of suchmethods are performed by the control system 640 in response to processor645 executing one or more sequences of one or more instructions. The oneor more instructions might be incorporated into an operating systemand/or other code that may be contained in memory 650, such as anapplication program. Such instructions may be read into memory 650 fromcomputer readable media 680, such as one or more of the storagedevice(s) (not pictured).

Alternative Dichroic Beam Combiner Architecture

FIG. 7 illustrates an alternative architecture for transmitting widelyspaced wavelength beams, in single mode operation, from a single pitchhead, and to a corresponding single catch head, with a dichroic beamcombiner 700, in accordance with various embodiments. A dichroic beamcombiner 700 is provided in each transmitting pitch head, catch head, orboth the pitch and catch heads of a widely spaced wavelength TDLASsystem.

Dichroic beam combiner 700 comprises a housing 730 having a firstdichroic element 705 and a second dichroic element 710. Each of thedichroic elements 705, 710 acts as a dichroic beamsplitter or mirrorthat reflects light of a specific wavelength or range of wavelengths,while allowing light at other wavelengths to pass through. For example,according to one set of embodiments, the single-mode fiber 715 may beused to transmit 2330 nm wavelength light, single-mode fiber 720 is usedto transmit 1350 nm light, and single-mode fiber 725 is used to transmit760 nm light. Thus, the dichroic elements 705, 710 are selected to allow2330 nm light to pass through, with dichroic element 705 reflectinglight at 1350 nm, and dichroic element 710 reflecting light at 760 nm,but also allowing 1350 nm light to pass.

Thus, each wavelength of laser beam enters the dichroic beam combiner700 via a respective single-mode fiber 715, 720, 725 appropriate forthat wavelength, with each of the single-mode fibers 715, 720, and 725optically coupled to the housing 730. The housing 730, single-modeoptical fibers 715, 720, 725 and dichroic elements 705, 710 areconfigured and aligned to produce a wavelength-combined beam that iscollimated through collimating lens 735 at an exit aperture of thehousing 730.

Utilizing the dichroic beam combiner 700 architecture, either a TDM orWDM configuration may be utilized. For example, according to one set ofembodiments, the various wavelengths of light of may be transmitted inan alternating manner, with only one wavelength of light transmitted ata given time. In embodiments utilizing a TDM configuration, the catchhead may comprise a photodetector for directly receiving the transmittedsignal. Alternatively, a corresponding catch side dichroic beam(de)combiner may be utilized. According to another set of embodiments, aWDM configuration may be utilized, where each wavelength of light istransmitted simultaneously. In such a configuration, a corresponding setof dichroic beam combiners may be utilized.

Where a pair of corresponding pitch and catch side dichroic beamcombiners 700 is used, just as the pitch side dichroic beam combiner maybe used to produce a wavelength-combined beam, the catch side dichroicbeam combiner may be used to decombine the wavelength-combined beam. Forexample, in some embodiments, a pitch-side dichroic elements 705, 710may be selected to allow 2330 nm light to pass through, with dichroicelement 705 reflecting light at 1350 nm, and dichroic element 710reflecting light at 760 nm, but also allowing 1350 nm light to pass. Onthe receiving-side, the dichroic elements 705, 710 may likewise beselected to allow 2330 nm light to pass through, but have dichroicelement 710 on the catch side reflect light at 760 nm, while allowinglight at 1350 nm and 2330 nm to pass through, dichroic element 705 onthe catch side reflect light at 1350 nm, but allow light at 2330 nm topass through.

In further embodiments, the dichroic beam combiners may also be utilizedin combination with the fiber bundle assemblies as described withrespect to the above embodiments, as well as the auto-alignment systemdescribed with respect to the fiber bundle assemblies.

While the procedures of the methods and processes described herein aredescribed in a particular order for ease of description, unless thecontext dictates otherwise, various procedures may be reordered, added,and/or omitted in accordance with various embodiments. Moreover, theprocedures described with respect to one method or process may beincorporated within other described methods or processes; likewise,system components described according to a particular structuralarchitecture and/or with respect to one system may be organized inalternative structural architectures and/or incorporated within otherdescribed systems. Hence, while various embodiments are describedwith—or without—certain features for ease of description and toillustrate exemplary aspects of those embodiments, the variouscomponents and/or features described herein with respect to a particularembodiment can be substituted, added and/or subtracted from among otherdescribed embodiments, unless the context dictates otherwise.Consequently, although several exemplary embodiments are describedabove, it will be appreciated that the invention is intended to coverall modifications and equivalents within the scope of the followingclaims.

What is claimed is:
 1. A system for measuring a concentration of atleast one target species comprising: a first and second tunable diodelaser, the first tunable diode laser generating laser light at a firstwavelength, the second tunable diode laser generating laser light at asecond wavelength, wherein the first wavelength and the secondwavelength correspond to respective absorption lines of the at least onetarget species; a first optical fiber having a proximal end and a distalend, the first optical fiber optically coupled to the first tunablediode laser at the proximal end, the first optical fiber not supportinga fundamental mode at the second wavelength; a second optical fiberhaving a proximal end and a distal end, the second optical fiberoptically coupled to the second tunable diode laser at the proximal end,the second optical fiber not supporting a fundamental mode at the firstwavelength; a fiber bundle assembly including a first distal end of thefirst optical fiber and a second distal end of the second optical fiber;a pitch head (i) including a transmitting optic optically coupled to thefirst and second tunable diode lasers via the distal ends of the firstand second optical fibers, and (ii) being oriented to project respectivebeams from each of the first and second distal ends through ameasurement zone; a photodetector configured to detect an optical powerof light in the first and second wavelengths; and a catch head (i)located across the measurement zone from the pitch head, (ii) in opticalcommunication with the pitch head to receive the respective beams fromthe first and second distal ends and direct the respective beams to thephotodetector.
 2. The system of claim 1, the photodetector including: afirst photodetector layer configured to (i) detect light at the firstwavelength and (ii) transmit, as a transmitted signal, laser light atthe second wavelength; and a second photodetector layer configured todetect the transmitted signal.
 3. The system of claim 2, the firstphotodetector layer including a silicon photodetector, the secondphotodetector layer including an indium gallium arsenide (ex-InGaAs)photodetector.
 4. The system of claim 1, the pitch head including adichroic beam combiner configured to combine the respective beams fromthe first distal end and the second distal end into awavelength-combined beam.
 5. The system of claim 1, the pitch head beingoriented to project the respective beams from each of the first andsecond distal ends as a wavelength-combined beam that propagates throughthe measurement zone one, the catch head including a dichroic beamcombiner configured to separate the wavelength-combined beam into therespective beams from each of the first and second distal ends.
 6. Thesystem of claim 1, in the fiber bundle assembly, (i) the distal ends ofthe first and second optical fibers being stripped of their respectivecoatings; and (ii) a first fiber optic core of the first optical fiberand a second fiber optic core of the second optical fiber are arrangedwith their claddings adjacent to each other forming a bundledconfiguration.
 7. The system of claim 1, the fiber bundle assembly beingpart of the pitch head.
 8. A pitch head comprising: a first single-modeoptical fiber that supports a first fundamental mode at a firstwavelength and not supporting a second fundamental mode at a secondwavelength; a second single-mode optical fiber that supports the secondfundamental mode at the second wavelength and not supporting the firstfundamental mode at the first wavelength; a beam combiner configured toproject respective beams output from each of the first and the secondsingle-mode optical fibers as a wavelength-combined beam; and acollimating lens configured to collimate the wavelength-combined beam.9. The pitch head of claim 8, the beam combiner being a dichroic beamcombiner.
 10. The pitch head of claim 9, the dichroic beam combinerincluding: a first dichroic element configured to reflect the firstwavelength, transmit the second wavelength, and transmit a thirdwavelength that differs from each of the first wavelength and the secondwavelength.
 11. The pitch head of claim 10, the first, second, and thirdwavelengths being 760 nanometers, 1350 nanometers, and 2230 nanometers,respectively.
 12. The pitch head of claim 8, respective distal ends ofeach of the first and second single-mode optical fibers being strippedof their respective coatings, the beam combiner including: a fiberbundle in which the respective distal ends the first and second opticalfibers are arranged with their claddings adjacent to each other,coupling joint in which the respective distal ends converge to form thefiber bundle.
 13. The pitch head of claim 8, each of the firstwavelength and the second wavelength being selected from the groupconsisting of 760 nanometers, 1350 nanometers, 1559 nanometers, and 2330nanometers.
 14. A catch head comprising: a receiving optic configured tofocus a wavelength combined beam that includes a first beam having afirst wavelength and a second beam having a second wavelength; a beamseparator configured to separate the wavelength combined beam into thefirst beam and the second beam; and a photodetector configured to detectan optical power of light in the first and second wavelengths, thephotodetector being a dual band detector including: a firstphotodetector layer configured to (i) detect light at the firstwavelength and (ii) transmit, as a transmitted signal, laser light atthe second wavelength; and a second photodetector layer configured todetect the transmitted signal.
 15. The catch head of claim 14, the beamseparator being a dichroic beam separator including: a first dichroicelement configured to reflect the first wavelength, transmit the secondwavelength, and transmit a third wavelength that differs from each ofthe first wavelength and the second wavelength.
 16. The catch head ofclaim 15, the first, second, and third wavelengths being 760 nm, 1350nm, and 2230 nm, respectively.
 17. A catch head comprising: a receivingoptic configured to focus a wavelength combined beam that includes afirst beam having a first wavelength and a second beam having a secondwavelength; a beam separator configured to separate the wavelengthcombined beam into the first beam and the second beam; a photodetectorconfigured to detect an optical power of light in the first and secondwavelengths; a first single-mode optical fiber that supports a firstfundamental mode at the first wavelength and not supporting a secondfundamental mode at the second wavelength, a distal end of the firstsingle-mode optical fiber being stripped of its coating; a secondsingle-mode optical fiber that supports the second fundamental mode atthe second wavelength and not supporting the first fundamental mode atthe first wavelength, a distal end of the second single-mode opticalfiber being stripped of its coating; and a fiber bundle in which therespective distal ends the first and second single-mode optical arearranged with their claddings adjacent to each other.
 18. The catch headof claim 14, the first beam and the second beam being time divisionmultiplexed beams.
 19. The catch head of claim 17, the photodetectorbeing a dual band detector including: a first photodetector layerconfigured to (i) detect light at the first wavelength and (ii)transmit, as a transmitted signal, laser light at the second wavelength;and a second photodetector layer configured to detect the transmittedsignal.
 20. The catch head of claim 19, the first photodetector layerbeing a silicon PIN photodetector layer, and the second photodetectorlayer being an extended indium gallium arsenide photodetector layer.